International Comfort Products PAJ4, WJA4 Installation Manual
INSTALLATION INSTRUCTIONS
14 SEER R--410A Single--Package Air Conditioner
Single Phase 2 to 5 Nominal Tons
PAJ4, WJA4
IMPORTANT: Effective January 1, 2015, all split system and
packaged air conditioners must be installed pursuant to applicable
regional efficiency standards issued by the Department of Energy.
NOTE: Read the entire instruction manual before starting the
installation.
NOTE: Installer: Make sure the Owner’s Manual and Service
Instructions are left with the unit after installation.
TABLE OF CONTENTS
PAGE
SAFETY CONSIDERATIONS 2.........................
INTRODUCTION 2...................................
RECEIVING AND INSTALLA TION 2--10.................
Check Equipment 2..................................
Identify Unit 2....................................
Inspect Shipment 2.................................
Provide Unit Support 2...............................
Slab Mount 2.....................................
Ground Mount 2..................................
Provide Clearances 2.................................
Place Unit 2........................................
Select and Install Ductwork 3...........................
Installing factory--supplied duct flanges 3...............
Configuring Units for Downflow (Vertical) Discharge 9....
Connect Condensate Drain 9...........................
Install Electrical Connections 9.........................
High--Voltage Connections 9.........................
Routing Power Leads Into Unit 9......................
Connecting Ground Lead to Unit Ground 9..............
Routing Control Power Wires 10.....................
Accessory Electric Heat Wiring 10.....................
PRE--START --UP 10...................................
START--UP 11--17.....................................
Check for Refrigerant Leaks 11.........................
Start--Up Cooling and Make Adjustments 11...............
Checking Cooling and Heating Control Operation 11......
Refrigerant Charge 13................................
No Charge 13.....................................
Low Charge Cooling 13.............................
Indoor Airflow and Airflow Adjustments 13...............
Sequence of Operation 13.............................
Fan Operation 13..................................
Cooling Operation 13...............................
Continuous Fan 17.................................
Electric Resistance Heating 17........................
A10165
Fig. 1 -- Unit PAJ4, WJA4
Certified to leak 2% or less of nominal air conditioning CFM
delivered when pressurized to 1-- in. W.C. with all present air
inlets, air outlets, and condensate drain port(s) sealed.
MAINTENANCE 18--21................................
Air Filter 18........................................
Unit Top Removal 18.................................
Indoor Blower and Motor 18...........................
Outdoor Coil, Indoor Coil, and Condensate Drain Pan 19.....
Outdoor Fan Adjustment 19............................
Electrical Controls and Wiring 19.......................
Refrigerant Circuit 20.................................
Indoor Airflow 20...................................
Metering Devices 20.................................
High Flow Valves 20.................................
High Pressure Switch 20..............................
R--410A Compressor 20...............................
Refrigerant 20......................................
Compressor Oil 20...................................
Servicing Systems on Roof with Synthetic Materials 20......
Synthetic Roof Precautionary Procedure 21................
Liquid Line Filter Drier 21.............................
R--410A Refrigerant Charging 21.......................
TROUBLESHOOTING 21..............................
START--UP CHECKLIST 21............................
Specifications are subject to change without notice.
426 01 1707 01 03/2015
SAFETY CONSIDERATIONS
Installation and servicing of this equipment can be hazardous due
to mechanical and electrical components. Only trained and
qualified personnel should install, repair, or service this equipment.
Untrained personnel can perform basic maintenance functions such
as cleaning and replacing air filters. All other operations must be
performed by trained service personnel. When working on this
equipment, observe precautions in the literature, on tags, and on
labels attached to or shipped with the unit and other safety
precautions that may apply.
Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Use quenching cloth for brazing operations.
Have fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions included in
literature and attached to the unit. Consult local building codes, the
current editions of the National Electrical Code (NEC) NFPA 70
and NFPA 90B--Installation Warm Air Heating and A/C Systems
(Residential). In Canada refer to the current editions of the
Canadian Electrical Code CSA C22.1.
Recognize safety information. This is the safety--alert symbol
When you see this symbol on the unit and in instructions or manuals, be alert to the potential for personal injury. Understand these
P AJ4, WJA4
signal words: DANGER, WARNING, and CAUTION. These
words are used with the safety--alert symbol. DANGER identifies
the most serious hazards which will result in severe personal injury
or death. WARNING signifies hazards which could result in personal injury or death. CAUTION is used to identify unsafe practices which may result in minor personal injury or product and property damage. NOTE is used to highlight suggestions which will
result in enhanced installation, reliability, or operation.
!
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal
injury or death.
Before installing or servicing system, always turn off main
power to system and install lockout tag. There may be
more than one disconnect switch. Turn off accessory heater
power switch if applicable.
!
CUT HAZARD
Failure to follow this caution may result in personal injury.
Sheet metal parts may have sharp edges or burrs. Use care
and wear appropriate clothing, safety glasses and gloves
when handling parts, and servicing equipment.
!
PERSONAL INJURY AND ENVIRONMENTAL
HAZARD
Failure to relieve system pressure could result in personal
injury and/or death.
1. Relieve pressure and recover all refrigerant before
servicing existing equipment, and before final unit disposal.
Use all service ports and open all flow--control devices,
including solenoid valves.
2. Federal regulations require that you do not vent
refrigerant into the atmosphere. Recover during system
repair or final unit disposal.
2 42601170701
CAUTION
WARNING
Specifications are subj ec t to change wi thout notice.
The PAJ4 and WJA4 packaged air conditioners are fully
self--contained and designed for outdoor installation (See Fig. 1).
Standard units are shipped in a horizontal--discharge configuration
for installation on a ground-- level slab or directly on the ground, if
local codes permit. Standard units can be converted to downflow
(vertical) discharge configurations for rooftop applications with a
field supplied plenum.
RECEIVING AND INSTALLATION
Step 1 — Check Equipment
IDENTIFY UNIT
The unit model number and serial number are printed on the unit
informative plate. Check this information against shipping papers.
INSPECT SHIPMENT
Inspect for shipping damage while unit is still on shipping pallet. If
unit appears to be damaged or is torn loose from its anchorage,
have it examined by transportation inspectors before removal.
Forward claim papers directly to transportation company.
Manufacturer is not responsible for any damage incurred in transit.
.
Check all items against shipping list. Immediately notify the
nearest equipment distribution office if any item is missing. To
prevent loss or damage, leave all parts in original packages until
installation.
Step 2 — Provide Unit Support
For hurricane tie downs, contact distributor for details and PE
(Professional Engineering) Certificate, if required.
SLAB MOUNT
Place the unit on a solid, level concrete pad that is a minimum of 4
in. (101.6 mm) thick with 2 in. (50.8 mm) above grade. The slab
should extend approximately 2 in. (50.8 mm) beyond the casing on
all 4 sides of the unit. Do not secure the unit to the slab except
when required by local codes.
A 6--in. (152.4 mm) wide gravel apron should be used around the
flat surface to prevent airflow blockage by grass or shrubs. The
unit should be level within 1/4 in. (6.4 mm). This is necessary for
the unit drain to function properly.
GROUND MOUNT
The unit may be installed either on a slab or placed directly on the
ground if local codes permit. Place the unit on level ground
prepared with gravel for condensate discharge.
Step 3 — Provide Clearances
The required minimum service clearances are shown in Fig. 4 and
Fig. 5. Adequate ventilation and outdoor air must be provided.
The outdoor fan draws air through the outdoor coil and discharges
it through the top fan grille. Be sure that the fan discharge does not
recirculate to the outdoor coil. Do not locate the unit in either a
corner or under an overhead obstruction. The minimum clearance
under a partial overhang (such as a normal house overhang) is 48
in. (1219 mm) above the unit top. The maximum horizontal
extension of a partial overhang must not exceed 48 in. (1219 mm).
IMPORTANT: Do not restrict outdoor airflow. An air restriction
at either the outdoor-- air inlet or the fan discharge may be
detrimental to compressor life.
Do not place the unit where water, ice, or snow from an overhang
or roof will damage or flood the unit. Do not install the unit on
carpeting or other combustible materials. Slab--mounted units
should be at least 4 in. (102 mm) above the highest expected water
and runoff levels. Do not use unit if it has been under water.
Step 4 — Place Unit
Unit can be moved with the rigging holds provided in the unit
base. Refer to table 1 for shipping weights. Use extreme caution to
prevent damage when moving the unit. Unit must remain in an
upright position during all moving operations. The unit must be
level with in 1/4 in. (6.4 mm) for proper condensate drainage; the
INTRODUCTION
ground-- level pad must be level before setting the unit in place.
When a field--fabricated support is used, be sure that the support is
level and that it properly supports the unit.
Step 5 — Select and Install Ductwork
The design and installation of the duct system must be in
accordance with the standards of the NFPA for installation of
non--residence type air conditioning and ventilating systems,
NFPA 90A or residence type, NFPA 90B and/or local codes and
ordinances.
Select and size ductwork, supply-- air registers, and return air grilles
according to ASHRAE (American Society of Heating,
Refrigeration, and Air Conditioning Engineers) recommendations.
Use the duct flanges provided on the supply-- and return--air
openings on the side of the unit. See Fig. 4 and Fig. 5 for
connection sizes and locations. The 14--in. (356 mm) round or 14
x 20 in. (356 x 508mm) rectangular duct collars are shipped
inside the unit attached to the base pan in the indoor blower
compartment. They are field--installed and mu st be removed
from the indoor blower compartment prior to start--up, even if
they are not used for installation. If a corrugated shipping
block is used under the blower housing, remove and discard
the block and label.
When designing and installing ductwork, consider the following:
!
CAUTION
UNIT DAMAGE HAZARD
Failure to follow this caution may result in damage to unit
components.
When connecting ductwork to units, do not drill deeper
than 3/4 in. (19.1 mm) in shaded area shown in Fig. 2 or
coil may be damaged.
19.17 in.
(487 mm)
3.92 in.
(100 mm)
flexible duct is used, insert a sheet metal sleeve inside duct. Heat
resistant duct connector (or sheet metal sleeve) must extend 24--in.
(610 mm) from electric heater element.
3. Size ductwork for cooling air quantity (cfm). The minimum
air quantity for proper electric heater operation is listed in
Table 2. Heater limit switches may trip at air quantities
below those recommended.
4. Seal, insulate, and weatherproof all external ductwork. Seal,
insulate and cover with a vapor barrier all ductwork passing
through conditioned spaces. Follow latest Sheet Metal and
Air Conditioning Contractors National Association
(SMACNA) and Air Conditioning Contractors Association
(ACCA) minimum installation standards for residential
heating and air conditioning systems.
5. Secure all ducts to building structure. Flash, weatherproof,
and vibration--isolate duct openings in wall or roof
according to good construction practices.
Fig. 8 shows a typical duct system with unit installed.
Installing factory--supplied duct flanges;
For 24, 30, and 36 sizes:
S Two round 14--in. (356 mm) duct collars are factory supplied.
S Line up the 6 holes in the duct collar with the pre-- drilled holes
in the side panel.
S Fasten duct collar to side panel using field-- supplied screws.
For 42, 48, and 60 sizes (See Fig. 3):
S One round 14--in. (356 mm) duct collar for the supply air
connections and two “L” brackets for the 14--in. x 20--in. (356 x
508 mm) return air connection are factory-- supplied.
S Line up the 6 holes in the supply duct collar with the pre--drilled
holes in the side panel. Fasten duct collar to side panel using
field--supplied screws.
S For the return, remove the 4 screws on the left side of the return
and install one of the “L” flanges on the left side by replacing
the 4 screws. Using the 2 dimples below the return, align the
bottom of the “L” flange with the two dimples and attach using
filed--supplied thread--cutting screws.
For the second “L” flange, align flange with the three dimples to
the right of the return and the two dimples above the return and
attach using field--supplied thread--cutting screws.
NOTE: The factory--installed screws to the right of the return
should not be removed in this process.
P AJ4, WJA4
3 Factory Installed Screws
(Must not be removed)
Remove 4 screws from left side
of duct opening and reuse to
install the left half of duct
flange.
A10021
Fig. 2 -- Area Not to be Drilled More Than 3/4--in. (19.1 mm)
Deep
1. All units should have field-- supplied filters installed in the
return--air side of the unit. Recommended sizes for filters are
shown in Table 1.
2. Avoid abrupt duct size increases and reductions. Abrupt
change in duct size adversely affects air performance.
IMPORTANT: Use flexible connectors between ductwork and
unit to prevent transmission of vibration. Use suitable gaskets to
Install supply duct flange
as shown into existing holes
with field-supplied screws.
X = Factory dimples for duct flange attachment.
ensure weather tight and airtight seal. When electric heat is
installed, use fireproof canvas (or similar heat resistant material)
Fig. 3 -- Installing Factory--Supplied Duct Flanges
connector between ductwork and unit discharge connection. If
42601170701 3
Specifications are subj ec t to change wi thout notice.
A10081
P AJ4, WJA4
A14411
Fig. 4 -- Unit Base Dimensions, PAJ4 024 --036
4 42601170701
Specifications are subj ec t to change wi thout notice.
P AJ4, WJA4
A14412
Fig. 5 -- Unit Base Dimensions, PAJ4 042--060
42601170701 5
Specifications are subj ec t to change wi thout notice.
P AJ4, WJA4
A14446
Fig. 6 -- Unit Base Dimensions, WJA4 024--036
6 42601170701
Specifications are subj ec t to change wi thout notice.
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